9. Technical data ...................................................................................................................14
2
FastMig KMS 400 AS
1. PREFACE
1.1 General
Congratulations on choosing the FastMig welding equipment. Used correctly, Kemppi
products can signicantly increase the productivity of your welding, and provide years of
economical service.
This operating manual contains important information on the use, maintenance and safety of
your Kemppi product. The technical specications of the equipment can be found at the end
of the manual.
Please read the manual carefully before using the equipment for the rst time. For your
own safety and that of your working environment, pay particular attention to the safety
instructions in the manual.
For more information on Kemppi products, contact Kemppi Oy, consult an authorised Kemppi
dealer, or visit the Kemppi web site at www.kemppi.com.
The specications presented in this manual are subject to change without prior notice.
Important notes
Items in the manual that require particular attention in order to minimise damage and
personal harm are indicated with the ’NOTE!’ notation. Read these sections carefully and follow
their instructions.
Disclaimer
While every eort has been made to ensure that the information contained in this guide
is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi
reserves the right to change the specication of the product described at any time without
prior notice. Do not copy, record, reproduce or transmit the contents of this guide without
prior permission from Kemppi.
EN
1.2 About FastMig KMS AS product
FastMig KMS 400 AS is CC (constant current) / CV (constant voltage) power source designed
for demanding professional use. It is suitable for MMA and MIG welding in DC.
FastMig KMS 400 AS is compatible with MSF, MXF and ArcFeed wire feeders.
The product is packed in specially designed transport cartons. However, before use always
make sure the products have not been damaged during transportation.
Check also that you have received the components you ordered and the instruction manuals
needed, as described in the Quick start guide pack. Product packaging material is recyclable.
NOTE! When moving the welding machine, always lift it from the handle, never pull it from the
welding gun or other cables.
Operating environment
This machine is suitable for both indoor and outdoor use. Always make sure that the air ow to
the machine is unrestricted. The recommended operating temperature range is –20…+40°C.
Please ensure you read the safety instructions concerning operating environments supplied in
this manual.
Distribution network
All regular electrical devices without special circuits generates harmonic currents into the
distribution network. High rates of harmonic current may cause losses and disturbance to
some equipments.
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
is greater than or equal to 4.7 MVA at the interface point between the user’s supply and
the public supply network. It is the responsibility of the installer or user of the equipment
to ensure, by consultation with the distribution network operator if necessary, that the
equipment is connected only to a supply with a short-circuit power Ssc greater than or equal
to 4.7 MVA.
4
FastMig KMS 400 AS
2.2 Machine introduction
H11
S11
H12
X14
X12
F11
H11
H12
S11
X11, X13
X11
Fuse for connection for control table6.3 A delayed
Signal lampI/O
Warning lamp for thermal protection
Main switchI/O
Welding connectionparallel
X13
X12
X14 , X15
01
2.3 Positioning and location of the machine
Place the machine on a rm, dry and level surface. Where possible, do not allow dust or other
impurities to enter the machines cooling air ow. Preferably site the machine above oor level;
for example on a suitable carriage unit.
Notes for positioning the machine
• The surface inclination should not exceed 15 degrees.
• Ensure the free circulation of the cooling air. There must be at least 20 cm of free space in
front of and behind the machine for cooling air to circulate.
• Protect the machine against heavy rain and direct sunshine.
NOTE! The machine should not be operated in the rain as the protection class of the machine,
IP23S, allows for outside preserving and storage only.
01
6,3A
Earth connection
Connection for control cableparallel
Inlet of mains cable
F11
X15
EN
NOTE! Never aim metallic grinding spray/sparks towards the equipment.
NOTE! Always check before use that the interconnecting cable, shielding gas hose, earth return
lead/clamp, and mains cable is in a serviceable condition. Ensure that connectors are correctly
fastened. Lose connectors can impair welding performance and damage connectors.
FastMig power sources are delivered as standard with 5 meters of mains power cable. No
mains plug is tted at the Kemppi factory.
NOTE! If local country based regulations state an alternative power cable is required, the mains
cable must be replaced in conformity with the regulations. Connection and installation of the
mains cable and plug, should only be carried out by a suitably qualied person.
Remove the machine cover plate to enable mounting of a mains cable. FastMig Pulse power
sources can be connected to the mains supply of 400 V 3~ .
If changing the mains cable take into consideration the following:
The cable is entered into the machine through the inlet ring on the rear panel of the machine
and fastened with a cable clamp. The phase conductors of the cable are coupled to connectors
L1, L2 and L3. The earth protection coloured green-yellow is coupled to the marked connector
. If you are using 5-lead cable, do not connect the neutral conductor.
EN
Sizes of the mains cables and fuse ratings for the machine at 100 % duty cycle are specied in
the table below:
Rated voltageMains voltage rangeFuses, slow-blowConnection cable *) mm²
KMS 300 400 V 3~360 V – 440 V20 A4 x 6.0 S
KMS 400 400 V 3~360 V – 440 V25 A4 x 6.0 S
KMS 500 400 V 3~360 V – 440 V35 A4 x 6.0 S
*) In cables of S type there is a protective grounding conductor coloured green-yellow.
2.6 Welding and earth cables
Recommended copper cables with cross-sectional area are as follows:
FastMig KMS 400 AS 70 – 90 mm²
In enclosed table are shown typical load capacities of rubber insulated copper cables, when
ambient temperature is 25 °C and lead temperature is 85 °C.
CableDuty cycle EDVoltage loss / 10 m
100 %60 %30 %
50 mm²285 A370 A520 A0,35 V / 100 A
70 mm²355 A460 A650 A0,25 V / 100 A
95 mm²430 A560 A790 A0,18 V / 100 A
Do not overload welding cables due to voltage losses and heating.
Fasten the earth clamp of the return current cable carefully, preferably direct onto the piece to
be welded. The contact surface of the earth clamp should always be as large as possible.
Clean the fastening surface from paint and rust.
• When CV is selected, parameter name ’dYn’ and the adjustable value between -9 ... 9 are shown
• When CC/MMA is selected, parameter name ’Arc’ and the adjustable value between -9 ... 9 are
shown
• In MXF mode the dynamics cannot be adjusted with the AS panel and ’--- ---’ is shown. In this case
the adjustment is done through the wire feeder panel
CC/MMA = Constant current mode. Selection with a long press. Selected when operated with ArcFeed
with CC-mode or MMA welding
MXF mode = Use with MSF or MXF feeders
CV mode = Constant Voltage. Selected when operating with ArcFeed CV-mode
Remote selection
• In CC/MMA mode the current can be adjusted with the remote
• In CV mode the voltage can be adjusted with the remote
MIG/MAG welding
FastMig KMS AS is designed for MIG/MAG welding with either the Kemppi ArcFeed voltage
sensing wire feed unit, or FastMig series MSF and MXF wire feeding units. When using MSF or
MXF wire feed units, connect the unit as described in picture on page 6, and select the MXF
mode from the AS panel. For further information see MSF or MXF manuals.
When you use the ArcFeed voltage sensing wire feed unit, you must select either CC or CV
(Constant Current or Constant Voltage) mode from the AS control panel. Ensure that the
ArcFeed control panel has been set to correspond with the power source control panel. For
example if power source is set to CC mode, the ArcFeed should also be set to CC mode. In CV
mode FastMig AS has two welding programs for ArcFeed welding: one for self shielding ller
wires and the other for standard cored and solid ller wires. The welding program can be
changed in SETUP function.
It is possible to connect MSF or MXF and ArcFeed feeders to FastMig KMS AS power source
simultaneously. For example, this can be an ecient combination when using Kemppi
8
FastMig KMS 400 AS
WiseRoot process for root pass welding and then completing hot pass and ller runs with
ArcFeed system using self-shielded ller wire.
MMA welding
FastMig KMS AS is also suitable for MMA welding with basic or rutile electrodes. MMA welding
works with CC (Constant current) mode set from the AS power source panel.
NOTE! In CC/MMA mode FastMig KMS AS has two welding programs: one for ArcFeed CC welding
and the other for MMA welding. The desired welding program can be chosen from the KMS AS
‘SETUP’ function.
TIG welding
By connecting MasterTig LT 250 to FastMig M with AS panel, TIG welding can be done. You
must select either CC or CV (Constant Current or Constant Voltage) mode from the AS control
panel.
2.8 Setup functions
With a long press of the SETUP button you can move to the Setup menu
Start Power
Device address
Welding program CC/MMA
Welding program CV
Restore factory settings
Remote control
StA-9 ... +90Strength of start pulse
Add3 or 66System bus address. Each device in same system
must have dierent address.
ProStl, FEEStI is for MMA welding FEE is for ArcFeed
ProStd, InSInS is for innershield wires Std for other wires
FACOFF, PAn, ALL OFFRestores factory settings, when PAn or ALL is
selected
rcOFF, onOFFManual control / remote control unit selection
3. OPERATION CONTROL SWITCHES AND POTENTIOMETERS
3.1 Main switch I/O
When you turn the switch into I-position, pilot lamp H11 on the front face is illuminated and
the machine is ready for use.
NOTE! Always turn the machine on and o with the mains switch, never use the mains plugs as a
switch.
3.2 Pilot lamps
The pilot lamps of the machine report the electric operation:
The green pilot lamp H11 when lit indicates that the machine is on and ready for use and it is
connected to the mains supply with the main switch in the I-position.
H12 indicates when lit that the thermal protection of the machine has been activated due to
over heating. The cooling fan will continue to run and cool the machine down and when the
lamp is o the machine is ready to weld.
EN
3.3 Operation of cooling fan
In FastMig KMS 400 AS power source there is two simultaneously operating fans.
• The fan is started for a moment when main switch is placed into position I.
• The fan will start during welding as the machine heats up and it will run for 1 to 10
NOTE! Many of these checks may be carried out by the operator. However certain checks relating to
mains power must be completed by an authorised trained electrician.
10
FastMig KMS 400 AS
5. MAINTENANCE
When considering and planning routine maintenance, please consider the frequency of
machine use and the working environment.
Correct operation of the machine and regular maintenance will help you avoid unnecessary
downtime and equipment failure.
NOTE! Disconnect the machine from the mains before handling the electrical cables.
5.1 Daily maintenance
• Check the overall condition of the welding gun. Remove welding spatter from the
contact tip and clean the gas nozzle. Replace worn or damaged parts. Only use original
Kemppi spare parts.
• Check the condition and connection of the welding circuit components: welding gun,
earth return cable and clamp, sockets and connectors.
• Check the condition of the feed rolls, needle bearings and shafts. Clean and lubricate
bearings and shafts with a small quantity of light machine oil if necessary. Assemble,
adjust and test function.
5.2 Periodic maintenance
NOTE! Periodic maintenance should only be carried out by a suitably qualied person. Disconnect
the plug of the machine from the mains socket and wait approx.2 minutes (capacitor charge)
before removing the cover plate.
Check at least every half year:
• Electric connectors of the machine – clean any oxidized parts and tighten loose
connections.
NOTE! You must know the correct tension torques values before starting the reparation of the loose
joints.
Clean the inner parts of the machine from dust and dirt e.g. with a soft brush and vacuum
cleaner. Also clean the ventilation net behind the front grill.
Do not use compressed air, there is a risk that the dirt will compact even more tightly into
gaps of cooling proles.
Do not use pressure washing devices.
Only an authorized trained electrician should carry out repairs to Kemppi machines.
5.3 Service shop maintenance
Kemppi Service Workshops complete maintenance according to their Kemppi service
agreement.
The major points in the maintenance procedure are listed as follows:
• Cleaning of the machine
• Checking and maintenance of the welding tools
• Checking of connectors, switches and potentiometers
• Checking of electric connections
• Checking of mains cable and plug
• Damaged parts or parts in bad condition are replaced by new ones
• Maintenance testing.
• Operation and performance values of the machine are checked, and when necessary
Should you experience a malfunction from your machine, please consult the basic
troubleshooting text above rst, and complete some basic checks. If the machine malfunction
cannot be corrected with these measures, contact your KEMPPI maintenance service
workshop.
6.1 Operation of the overload protection
Yellow thermal protection lamp is lit when the thermostat is operating due to loading beyond
the stated duty cycle.
The thermostat will operate, if machine is continuously loaded over rated values or cooling air
circulation is blocked.
Internal fans will cool the machine, and when the pilot lamp is not lit the machine is
automatically ready for welding.
6.2 Control fuses
Fuse, 6.3 A delayed, on the rear wall of machine provides protection for auxiliary devices.
NOTE! Use same type and rating of fuse which is marked beside the fuse adapter. Damage caused
by a wrong type fuse is not covered by the guarantee.
6.3 Under- and overvoltages in the mains supply
Primary circuits of the machine are protected against sudden, transient overvoltages. The
machine is designed to withstand 3 x 440 V voltage continuously (see technical data). Ensure
that voltage is kept within this admissible limit, especially when the mains supply is provided
by a combustion engine generator. If the mains has under voltage (under approx. 300 V) or
overvoltage (over approx. 480 V) machine control stops operation automatically.
6.4 Loss of a phase in the mains supply
Loss of a main power phase causes noticeably poor welding properties. In some cases the
machine won't start at all. Loss of a phase can be due to following:
• Blowing of mains supply fuse
• Defective mains cable
• Bad connection of mains connection cable on terminal block or plug of machine.
7. DISPOSAL OF THE MACHINE
Do not dispose of electrical equipment with normal waste!
In observance of European Directive 2002/96/EC on waste electrical and electronic
equipment, and its implementation in accordance with national law, electrical equipment
that has reached the end of its life must be collected separately and taken to an appropriate
environmentally responsible recycling facility.
The owner of the equipment is obliged to deliver a decommissioned unit to a regional
collection centre, per the instructions of local authorities or a Kemppi representative. By
applying this European Directive you will improve the environment and human health.
12
FastMig KMS 400 AS
8. ORDERING NUMBERS
FastMig KMS 400 AS
Wire feeders
ArcFeed 200
ArcFeed 300
ArcFeed 300P
MXF 65
MXF 67
MXF 63
MXF 65
MXF 67
MXF 63
Panels for MSF and MXF feeders
SF 51
SF 52W
SF 53W
SF 54
Accessories
Return current cable
Return current cable
Cable for MMA welding
Cable for MMA welding
Remote controlled interconnecting cable
Cooling unit Fastcool 10
Transport unit PM 500
Gun holder GH 30
Max. welding voltage
Open circuit voltage
Open circuit power
Efficiency at max. current
Power factor at max. current
Operating temperature range
Storage temperature range
Degree of protection
EMC class
Minimun short circuit power Ssc of supply network*
External dimensions (LxWxH)
Weight
Voltage supply for auxiliary devices
X14, X15
Voltage supply for cooling unit
46 V
50 V
25 W
87 %
0.9
-20 ... +40 ºC
-40 ... +60 ºC
IP23S
A
4.7 MVA
590x230x430 mm
35 kg
50 V DC
fuse 6.3 A delayed
1~ 400 V AC and 24 V DC
14
* See paragraph 3.1.
FastMig KMS 400 AS
KEMPPI OY
Kempinkatu 1
PL 13
FIN-15801 LAHTI
FINLAND
Tel +358 3 899 11
Telefax +358 3 899 428
export@kemppi.com
www.kemppi.com
Polkovaya str. 1, Building 6
127018 MOSCOW
RUSSIA
Tel +7 495 240 84 03
Telefax +7 495 240 84 07
info.ru@kemppi.com
ООО КЕМППИ
ул. Полковая 1, строение 6
127018 Москва
Tel +7 495 240 84 03
Telefax +7 495 240 84 07
info.ru@kemppi.com
KEMPPI, TRADING (BEIJING) COMPANY LTD
Unit 105, 1/F, Building #1,
No. 26 Xihuan South Rd.,
Beijing Economic-Technological Development
Area (BDA),
100176 BEIJING
CHINA
Tel +86-10-6787 6064
+86-10-6787 1282
Telefax +86-10-6787 5259
sales.cn@kemppi.com
LAKSHMI TOWERS
New No. 2/770,
First Main Road,
Kazura Garden,
Neelankarai,
CHENNAI - 600 041
TAMIL NADU
Tel +91-44-4567 1200
Telefax +91-44-4567 1234
sales.india@kemppi.com
KEMPPI WELDING SOLUTIONS SDN BHD
No 12A, Jalan TP5A,
Taman Perindustrian UEP,
47600 Subang Jaya,
SELANGOR, MALAYSIA
Tel +60 3 80207035
Telefax +60 3 80207835
sales.malaysia@kemppi.com
www.kemppi.com
1905320
1515
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